Control Global

Greg McMillan and Stan Weiner Speak with Electrochemical Measurements Expert Jim Gray About the pH Electrode and Its Full Potential as a Measuring Tool

Stan: A measurement is only as good as its calibration. The pH electrode has by far the greatest sensitivity and rangeability of any measurement in the process industry. The electrode can function well in a wide spectrum of process fluids and…

This State of Technology Report is a compendium of the latest trends articles, back-to-basics tutorials, application stories and product solutions recently published in the pages of Control—compiled by the editors and all together here in one convenient eBook.

Despite ongoing advances in instrumentation technology, specifying a flowmeter or level gauge that will reliably perform over the anticipated range of process conditions often remains a complex and subtle engineering task.
Dozens of niche…

Process plants and related facilities such as tank farms are filled with vessels, tanks and similar storage units, and most of these units could benefit from a system to measure, monitor and view inventory on a near real-time basis. "Logistical…

Additional information and wireless connectivity are further improving productivity, reliability and efficiency.

Like other facilities that have been using the HART Communication Protocol for any amount of time, previous recipients of the HART Plant of the Year Award have been busy reaping even more of the benefits the technology provides. These benefits…

BLH Nobel Introduced a System That Quickly and Easily Checks Weighing Systems for Wiring and Mechanical Faults

Load cell weighing systems solve some of the knottiest problems in batch and level control by directly measuring masses of solids and liquids as they're accumulated, dispensed or conveyed. But the load cells must be installed and wired properly, and the load structure must be engineered and constructed correctly to distribute the measured load as axial forces on the cells. What appear on the surface to be simple wiring and construction tasks have caused more than a few problems during commissioning and maintenance due to miswired or poorly made connections, distorted or binding structures, incorrectly installed load cells or rigid connections to adjacent equipment.
Such problems often are not found until a new installation is being…

Recent

Greg McMillan and Stan Weiner Speak with Electrochemical Measurements Expert Jim Gray About the pH Electrode and Its Full Potential as a Measuring Tool

Stan: A measurement is only as good as its calibration. The pH electrode has by far the greatest sensitivity and rangeability of any measurement in the process industry. The electrode can function well in a wide spectrum of process fluids and…

This month, the editors of Control browse the web to get you the latest online resources on loop control. Here's how you can stay in the loop!

This System Is Closed
This is a basic tutorial on closed-loop control systems. It covers the basic definitions and descriptions of how closed-loop systems work, a discussion of closed-loop summing points and how to use them, transfer functions, multi-loop closed-loop systems and closed-loop motor control. The direct link is www.electronics-tutorials.ws/systems/closed-loop-system.html.Electronics Tutorials www.electronics-tutorials.ws
PID Control
VeriCal in-situ calibration verification This is a basic discussion, with illustrations, of the principles of Proportional, Integral, Derivative (PID) and how it is used with controllers. It also covers tuning rules and starting settingf for common control loops. The direct link is at…

Through the looking glass of emerging technologies.

How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to see where there is…

A Frost & Sullivan report, "Programmable Logic Controllers Market," finds that the market earned revenues of $10.37 billion in 2013 and estimates this will reach $14.58 billion in 2018.

According to analyst firm Frost & Sullivan, the global PLC market, which witnessed a strong decline in growth in 2012 due to the uncertain economic scenario in the developed world, has bounced back. Since 2013, it has witnessed positive growth, particularly in the Asia-Pacific region, where the rebound has been fueled by increased activity, especially in the construction, water and wastewater and power industries.
A Frost & Sullivan report, "Programmable Logic Controllers Market," finds that the market earned revenues of $10.37 billion in 2013 and estimates this will reach $14.58 billion in 2018.
In Europe, the need to enhance efficiency and comply with regulations, as well as improve safety and control capabilities, are driving…

Through the looking glass of emerging technologies.

How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to see where there is…

Control Engineering Branches Out to Manage Critical Business Variables Such as Profitability, Risk, Asset Management and Cybersecurity

Most process engineers I talk to look back on the 1970s and 1980s as the heyday of control engineering, and in many ways it was. More engineers were focused on the applications of real-time control theory then than now. And when you look at how far…

The Latest in Computing Technology Is Here

VERSATILE AUTOMATION COMPUTERS These four new computers are designed for the challenging requirements of the machine automation industries. UNO-3073 and UNO-3073GL have Intel Celeron 1.1- MHz and 1.0-MHz processors; UNO-3083G and UNO-3085G have Intel Core i7 2.2- MHz processors. They have up to five PCI/PCIe expansion slots and support high-speed PCIe x16, x8, x4 and x1 cards and legacy PCI cards. Advantech Industrial Automation Group 800-205-7940www.advantech.com/ea
GAME-CHANGING PACs PACSystems RXi, a new control and computing platform, is designed for the needs of the industrial Internet. The core of the product family is a COM Express architecture with multi-core CPUs. Its configurations are unique in the industry, and able to…

Smart Drives, Mechatronics, Variable-Speed Drives and More Power Options

MEDIUM-VOLTAGE AC DRIVE MV1000 medium-voltage ac drives combine compact modular design, high efficiency and a good MTBF rate. Smart Harmonics technology reduces input total harmonic distortion to less than 2.5% without filters, which exceeds the requirements of IEEE519-1992. It also provides galvanic isolation between power input and output, and uses two 5-V step bridges per phase to generate a 17-level, line-to-line voltage output delivered to the motor. Yaskawa800-927-5292
VSD WITH SMARTSAltivar Process is a range of VSDs from 1 hp to 1,500 hp that come with embedded process knowledge, configurable on-board dashboards and a graphical HMI display. An advanced, secure, integrated web server lets operators access technical…

Since the goal is to control loop stability, the choice that gives you the best chance of that is the one to make.

Question:
Is there some general rule on when we should use =% (equal percentage) and when linear control valves? I know that the determining factor is the inherent flow characteristic, the flow vs. lift at constant pressure drop, or something like…

After six decades of developing on/off valve automation solutions, it might seem logical for Emerson Process Management to pause and take a well-deserved breather. But anyone who thinks that doesn't know how this company works. Just like the…

Smart Drives, Mechatronics, Variable-Speed Drives and More Power Options

MEDIUM-VOLTAGE AC DRIVE MV1000 medium-voltage ac drives combine compact modular design, high efficiency and a good MTBF rate. Smart Harmonics technology reduces input total harmonic distortion to less than 2.5% without filters, which exceeds the requirements of IEEE519-1992. It also provides galvanic isolation between power input and output, and uses two 5-V step bridges per phase to generate a 17-level, line-to-line voltage output delivered to the motor. Yaskawa800-927-5292
VSD WITH SMARTSAltivar Process is a range of VSDs from 1 hp to 1,500 hp that come with embedded process knowledge, configurable on-board dashboards and a graphical HMI display. An advanced, secure, integrated web server lets operators access technical…

Through the looking glass of emerging technologies.

How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to see where there is…

Through the looking glass of emerging technologies.

How might we expect emerging technologies to play out in the world of process control? Successfully predicting the future is difficult at best, so we sought out and consulted with industry visionaries and long-term planners to see where there is…

Local automation pros can learn about key industry developments, gain development hours and upgrade their outdoor skills

Automation professionals in the Los Angeles area will be able to update their professional knowledge, explore key automation trends, receive professional development hours, meet leading industry experts—and improve their outdoor skills—when Siemens brings its Process Automation Tour to Bass Pro Shops in Rancho Cucamonga, Calif., on March 26, 2015.
Session topics will include:
Industrial security for process automation, including a review of the standards (IEC 62443), organizations (NIST) and proper implementations of those standards
Alarm management, with a focus on meeting ISA-18.2, condition monitoring of critical assets and improving operator effectiveness
Process safety management update, including how to keep your system compliant…

The GX and GP Products Are the First of a New SmartDAC+ Product Family

Yokogawa has released the GX and GP Series of digital data acquisition systems, products that go far beyond functionality of the original paperless recorder. Complementing Yokogawa's DXA Advanced R4 series, the GX and GP bring some features that are…

Recent

Because Big Data is Really More of the Same Data, Engineers and Other End Users Find Ways to Take Advantage of New Sources of Intelligence

I'm sorry to be a downer at the start of a shiny New Year, but I'm continually reminded that most new and unfamiliar technical concepts are just more of the same old concepts. Big data is really more of the same data. The Internet of Things (IoT)…

Reader says "NERC CIP does not make the grid more secure or reliable."

In response to Joe Weiss' blog post of Jan. 19, I totally disagree about NERC CIP not making the grid more secure or reliable. Just a few reasons. I have seen where control systems were operated without malware and ultimately became infected. At…

Diagnosing a signaled instrument failure is tricky, time-consuming and usually is called for at a most inconvenient time, but better diagnostics are making the task easier.

Physical Layer Diagnostic Improvements
Why is it, after weeks of seemingly trouble-free plant operation, the phone rings on the holiday weekend when the goose is in the oven and the table is set for dinner? Fortunately for me, the crew on shift was…

A badly designed network is often the weakest link in the system.

IoT's Weakest Link
A common conversation among many industrial networking specialists these days revolves around whether we should be distinguishing between wired and wireless networks. WINA, of which I am chairman, is one organization taking a…

We are destined to have a multiplicity of protocols in our facilities.

Regarding, John Rezabek's February On the Bus column: I think we are destined to have a multiplicity of protocols in our facilities. Actuators and sensors will be at the level of the not-Internet of Things; Ethernet makes no sense there. But…

This white paper is the first in a series to outline a new epoch of industrial automation. All aspects of control system reliability, security and lifecycle cost have been rethought from first principles.

Open Secure Automation™ from Bedrock delivers new levels of ICS reliability, embedded security and unified automation performance at much lower life cycle costs. The mission starts with reinventing the backplane. Bedrock's Backplane Module Interconnect (BMI) is designed with an advanced architecture, industrial grade materials and passive fail-safe principles. With a new foundation, automation can be rebuilt. There is no other way.
This white paper is the first in a series to outline a new epoch of industrial automation. All aspects of control system reliability, security and lifecycle cost have been rethought from first principles.
Download the white paper titled "Revolution" and learn more.

Mobility's True Value Lies in Enabling New Possibilities

Rockwell Automation takes seriously the needs of its users to access information when on the go. For years now, they've offered the ability to send text or email notifications to mobile devices or replicate in-plant or desktop user interfaces on…

Reader says "NERC CIP does not make the grid more secure or reliable."

In response to Joe Weiss' blog post of Jan. 19, I totally disagree about NERC CIP not making the grid more secure or reliable. Just a few reasons. I have seen where control systems were operated without malware and ultimately became infected. At…

As project details take shape, look to collaborative platforms and decoupled hardware and software development paths to speed execution efforts

As early project visioning shifts into more detailed engineering, it's time to take a much closer look at how the latest automation technology and project execution methodologies can be brought to bear for project success. Key automation…

Local automation pros can learn about key industry developments, gain development hours and upgrade their outdoor skills

Automation professionals in the Los Angeles area will be able to update their professional knowledge, explore key automation trends, receive professional development hours, meet leading industry experts—and improve their outdoor skills—when Siemens brings its Process Automation Tour to Bass Pro Shops in Rancho Cucamonga, Calif., on March 26, 2015.
Session topics will include:
Industrial security for process automation, including a review of the standards (IEC 62443), organizations (NIST) and proper implementations of those standards
Alarm management, with a focus on meeting ISA-18.2, condition monitoring of critical assets and improving operator effectiveness
Process safety management update, including how to keep your system compliant…

Coca-Cola and GE Lighting Use Proficy Workflow, Historian, iFix HMI SCADA and Portal Software to Streamline Lighting and Refreshment Production

Seeing is believing, and bringing operational information into the light makes it usable by everyone in an enterprise—allowing them all to make faster, more productive decisions.
This enhanced awareness was especially useful at GE Lighting,…

As project details take shape, look to collaborative platforms and decoupled hardware and software development paths to speed execution efforts

As early project visioning shifts into more detailed engineering, it's time to take a much closer look at how the latest automation technology and project execution methodologies can be brought to bear for project success. Key automation…

Find out what certification ABB Canada received and what B&B ELectronics' new name is.

ABB's operations in Canada have been certified by TÜV SÜD as having in place and applying a functional safety management system (FSMS) for the design and engineering of safety instrumented system (SIS) projects in accordance with industry good practice safety standards. These standards include IEC 61508 and IEC 61511 for the integration and implementation of safety instrumented systems. Networking technology provider B&B Electronics has changed its name to B+B SmartWorx. While continuing to develop mission-critical network connectivity technology for remote or demanding environments, B+B SmartWorx is expanding into the emerging Internet of Things market and embedding intelligence throughout the network connectivity stack from edge…

The Department of Homeland Security wants to help you prevent, respond to and recover from cyber attacks.

As we go to press, the U.S. Congress is threatening to suspend funding for the Department of Homeland Security (DHS). Some members are even calling for its dissolution. But assuming it's still around when you read this, you might consider enlisting…

What do 9/11, the Detroit Bomber and ICS Security Have in Common?

By Walt Boyes, Editor in Chief
In his "Unfettered" blog post, "What do 9/11, the Detroit Bomber and ICS Security Have in Common," Joe Weiss makes a really good point: The result of all governments' responses to the Dec. 25 incident on the approach…

Recent

Will Electronic Marshalling Mean the End of the "Bespoke" Enclosure?

Unlike clothing fashions, enclosure styles don't change a lot from year to year. A 40-year-old enclosure doesn't stand out like your dad's leisure suit. After all, a big metal box is pretty much a big metal box, even with the added glitz of…

Migrating Provox DCS to DeltaV

Noltex LLC is a leading manufacturer of ethylene vinyl alcohol co-polymer. The company's facility in La Porte, Texas recently completed one of the first successful petrochemical industry migrations from a Provox DCS to a DeltaV digital automation system. The plant is extremely important to Noltex because it produces a unique ethylene vinyl alcohol co-polymer resin used to make a gas-barrier film component for food packaging. Sold under the trade name of Soarnol, this unique polymer is most commonly used to create an almost-invisible preservative barrier that prevents food products from oxidizing and spoiling.

The migration was planned as a like-for-like control conversion for the plant's distillation columns, brine water chillers, process gas compressors, and related equipment. Process control strategies were modified by the plant's process and operational managers to reflect plant operating experiences and the new system's strengths. The migration process continues, with additional like-for-like Provox to DeltaV migrations are planned for process trains in the manufacturing area in 2004 and 2005. Manufacturing process trains are run by later model Provoxredundant controllers and therefore, scheduled last.

While the existing DCS had been trouble-free, future reliability remained a question mark for the plant's managers. The Provox controllers had become hardware and software point-limited, which precluded adding new devices and logic to improve operational and other process efficiencies. Similarly, the DCS was maxed out when it came to the number of physical devices permitted on its data highway. To add capacity and reach current and future production goals, Noltex would have to add new hardware and process control capability.

The DCS also had data highway loading issues that resulted in scan times as long as 380 milliseconds and prompted concern about data latency. Compounding these issues was the state of the controller configuration which had been modified numerous times over the years and which made troubleshooting and modifications both time consuming and difficult. Lastly, Noltex's process engineers desired the flexibility to deploy bus-connected I/O, OPC, and serial communications, as well as initiate advanced control techniques such as fuzzy logic, neural networks, and model predictive control.

Path Forward

In 2000, Noltex formed a focused, dedicated improvement team to chart a path forward and develop and evaluate plans for the plant's existing DCS control system. This multi-disciplined team, comprised of representatives from operations, technical support, maintenance, engineering, and information technology had to decide whether to upgrade, replace, or migrate to new technology.

The first option the team explored was upgrading its current hardware with the latest HART Smart I/O controllers and new operator consoles. The team's analysis revealed this option did not take advantage of thr latest field device bus technologies nor advanced process control capabilities. Further, current-generation control system advancements such as system speed, configuration utilities, and system troubleshooting would also not be available. Noltex's improvement team members soon realized that future expansions via this technology platform over the long haul would be more costly than replacing the entire system with newer technology.

After evaluating system offerings from several DCS manufacturers the improvement team determined that migrating the existing DCS to Emerson Process Management's DeltaV was the best, most cost-effective choice.

To phase out different generations of controllers in an orderly fashion the implementation was planned in stages. The Provox simplex controllers were upgraded first, then the oldest redundant units second. Finally, the newest redundant controllers will be replaced during the final two project phases. In 2002, Noltex migrated the discrete control system from the plant's packaging area. In 2003, the compressors, solutions preparation, distillation, solvent recovery, demineralization process, and the utilities migration projects were completed. To complete the project, Noltex is now planning to migrate the existing manufacturing facilities in two separate phases.

Smart Field Device Upgrades Integral to Migration

In 1998 Noltex purchased asset management software and correspondingly started upgrading field devices in its existing production areas to the HART protocol. Subsequently, Noltex purchased all new instruments for the migration to the new system based on Foundation Fieldbus or HART communications protocols.

In 2002, Noltex upgraded several electro-pneumatic valve positioners to digital valve controllers (DVCs) which increased the total number of HART DVCs to more than 220. Via the valve-position feedback capabilities of the new DVCs, Noltex's system is now indicating actual valve position on the operator displays rather than having to settle for the old controller's less accurate implied valve position. The new smart field devices, combined with the DCS and the existing asset management software facilitate electronic storage of device configuration and calibrations. This system also helps Noltex process engineers and maintenance technicians monitor control valve degradation and the health status of the company's field devices.

As the project got under way, Noltex improvement team members became increasingly convinced that its control system migration project, along with the field device upgrades it undertook, would lay a solid foundation for current and future process control operations.

All Hardware Changed Out

Two choices were available when it came time to migrate the Distillation Area's process control system to the new DCS. The first choice was to remove all existing hardware except termination panels, pre-mount the controllers in new cabinets offsite, and prepare pluggable links between the termination panels and the control's I/O using a pre-fabricated flexible-connection cable system.

Choice two dictated removing all existinghardware and then installing the new hardware and termination panels in the empty cabinets. With either choice, field wiring remained, field devices did not require replacement, and the system software could be configured and tested prior to installation.

Employing a pre-fabricated cabling system is an ideal solution if cutover and startup must take place within a short time frame, but Noltex management had a scheduled an extended outage so the plant would be shut down during DCS implementation. Under these circumstances, the second option the better choice. Consequently, all the old hardware was removed, and because the new system has a smaller footprint, more room became available for future upgrades.

During this first phase of the project Noltex and vendor technicians replaced four (of 13 existing) redundant sets of controllers. To reduce cross-communications, I/O was reassigned among seven controllers (four of which were upgraded and three of which were not).Completing the new system's installation were small marshaling panels for field wiring (the previoussystem had no marshaling panels), interposing relays for discrete points, and installing multiconductor cables between marshaling panels and the DCS I/O.

Challenging Configuration

The new system was configured using graphical function block diagram and sequential function chart languages through a combination of manual work, plus the application of several Provox-to-DeltaV conversion utilities developed for the Noltex project by Puffer-Sweiven, a systems integrator located in Stafford, Texas. Because of the configuration's complexity, seven programmers, plus a Noltex liaison person worked full time for 12 weeks to finish this critical part of the project.

Most of January 2003 was spent defining the project's scope and developing the conversion utilities. During February and March Noltex concentrated on configuring functions and graphics in time for the April factory acceptance testing (FAT), installation and checkout in May, and startup in June.

The conversion utilities helped Noltex managers decide which points should be migrated to the new DCS and which should be transferred to the manufacturing area's Provox controllers. Correspondingly, some points in manufacturing area were best transferred to the new system's controllers. Other points were eliminated as they were no longer in service.

Also identified and listed by the conversion utilities were those control points whose information had to travel between DeltaV and Provox. Noltex's engineers decided that critical points would be hardwired, while informational points were to be passed through the Provox-to-DeltaV Integrator using OPC Mirror and Emerson utilities. For example, a pump might have I/O in DeltaV, but show up on both systems' graphical user interface and be commanded from either system. The upgrade was done so that operator function would be transparent regardless of which system had I/O control.

Utilities were of little help in loop configuration because many of the non-standard functions programmed into the Provoxloops are built into the new control system. If a utility was run to pull FST information out of Provoxconfigurations it ended up with unnecessary code. Basic loop functionality (alarms, ranges, tuning parameters, fail action, etc.) was converted from Provox using the new utilities. Associated interlocks and FSTs were configured manually by deciphering Provoxcode and implementing the same functions in the new DCS. A certain amount of intelligent re-engineering was thereby gained; mostly simplification, but accompanied by a certain degree of control improvement.

To confirm interlock design and keep the new DCS as clean as possible, interlocks and sequencing were also prepared manually. This allowed for technical review to correct errors or identify improvement opportunities. The interlock and sequence code configured in DeltaV function blocks was much simpler to read, troubleshoot, and modify than the coding custom FSTs in with the old system.

The four sets of redundant controllers have 300 to 350 device signal tags each, which left approximately 400 available for additional devices under the present license. The controllers memories are only 15-20% loaded, which allows for scan times at configured individual module rates.

Graphics Improved

To meet time constraints, the distillation system's 132 screens were jointly prepared by a third-party vendor and the Emerson Solutions Group. Utility tools were initially considered in order to convert the VAX graphics, but any gains realized from doing that would be more than offset by time spent cleaning up pages, etc. So, graphics were created from scratch using the new system's object-oriented design tools. Nevertheless, utilities were later used to correlate points with icons, check functionality behind color conditions, and perform other functions.

Noltex improvement team members established standards for display navigation and graphical representation of the process. To mitigate any issues resulting from changes to the operator interface, graphics were designed to resemble the old system'spages. In spite of that, graphics creation was expedited because programmers were able to take advantage of the new system's object-oriented dynamos. In the end, the interface's graphics were freshened, but the basic layout remained the same as far as the operators are concerned.

FAT Performed Offsite

Software and staged-hardware FAT took place separately over a three-week period. Everything in the listings and drawings created from the FSTs was checked carefully so that once the equipment was onsite, it could be plugged in and the I/O immediately checked. All hardware functions -- including interlocks -- were tested and all I/O was exercised. Function and input verification and I/O exercising were conducted using appropriate utilities, along with some custom graphics and code. This allowed hardware and software testing to occur simultaneously.

Pump Control Refined

Instrument stand and pumps run by DeltaV automation.

Prior to acceptance testing, the DCS system's manufacturer provided key Noltex personnel with on-site training. This training allowed for the early completion of the FAT and proved valuable during on-site checkout, commissioning, and startup. Software review was performed simultaneously by three separate teams comprised of a Noltex operator and process control specialist, plus a process control specialist supplied by Puffer-Sweiven, which also assisted Noltex with hardware acceptance testing.

After the FAT, installation crews completed hardware changeout during two long weeks of 10-hour days. After installation, Noltex engineers and specialists spent three weeks downloading device configurations, shooting every loop from the field to the new systems controllers, checking every interlock, double-checking graphics, and physically verifying that every motor ran and every device activated. All told, commissioning the new DCS, which began during the second week of installation, required seven I&E technicians, two process control system specialists and two board operators working 12-hour days.

In addition to the early training of key production personnel, on-site training was provided to operators and technicians. Training concentrated on understanding and using the logic in DeltaV Control Studio for troubleshooting. Puffer-Sweiven loaded the completed configuration and graphics, plus Mimic (www.mynah.com) simulation software, into an off-line DeltaV workstation so Noltex personnel could learn and practice operating the new systems.

Fresh Operator Interface

Freshened graphics, but based on previous system's iconography helped the transition to the new system.

Because of the hard work and concerted efforts of everyone involved, the automation upgrade project came together on-time and on-budget and startup was uneventful. Good product was made right off the bat. Based on operating experience gained since the migration, Noltex is experiencing a number of benefits as listed in Table 1.

The Future

In the very near future, Noltex plans to set up a permanent DCS system development/training hardware unit in the control room to train new technicians and operators, run refresher courses, allow tinkering and practicing, and prepare for bus-connected I/O in future projects. The unit will be especially helpful for learning bus commissioning, decommissioning, uploading, downloading, and changing configurations.

Noltex is in the process of evaluating the advanced control capabilities of the new DeltaV-based DCS, and the model-predictive controller is planned to replace some standard PID controller modules in difficult applications.Noltex operators are also using features built in to the new DCS such as Inspect for monitoring loop performance and Diagnostics for monitoring hardware. DeltaV version control and audit trail software has been added to monitor configuration changes as well. Meanwhile, Noltex process engineers and maintenance technicians continue to rely on the asset management software, but use it as a stand-alone system for monitoring and configuring smart devices.